Thermoplastic Impregnation Heating System
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Solution Overview
Problem
Current methods for manufacturing impregnated fibrous materials with thermoplastic polymers face challenges in achieving homogeneous impregnation, controlled porosity, and reproducible quality, particularly due to high viscosity issues with thermoplastic resins and the use of organic solvents, which lead to porosity, environmental risks, and reduced mechanical strength.
Innovation Solution
A method involving pre-impregnation of fibrous materials with thermoplastic polymers followed by a heating step using heat-conducting supporting parts and a heating system, excluding heated calendars, to achieve homogeneous impregnation to the core with reduced and controlled porosity, ensuring high fiber volume rates and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic polymers with high glass transition temperature are used for impregnation, then the mechanical strength and thermal properties of the composite material are improved, but the viscosity of the polymer becomes too high to allow satisfactory impregnation of the fibers
Solution Approach 1:
The patent applies preliminary action by pre-heating the thermoplastic polymer before impregnation to reduce its viscosity, making it easier to impregnate the fibers. After impregnation, the polymer is cooled and solidifies to provide the desired mechanical strength. This sequence of heating-impregnating-cooling resolves the contradiction between high viscosity (manufacturing difficulty) and high mechanical strength.
2Manufacturing precision
If organic solvents are used in the impregnation process, then the impregnation homogeneity is improved, but porosity increases and environmental risks arise
Solution Approach 1:
The patent extracts and eliminates organic solvents from the impregnation process by using alternative methods such as water-based solutions or direct melting of thermoplastic polymers. This removal of harmful solvents reduces porosity and environmental risks while maintaining impregnation homogeneity through controlled heating and cooling processes.
Solution Approach 2:
The patent changes the physical parameters of the impregnation process by controlling temperature, humidity, and pressure to achieve homogeneous impregnation without organic solvents. By precisely controlling these parameters during heating and cooling, the patent maintains uniform polymer distribution while avoiding the porosity and environmental issues associated with solvent-based methods.
3Productivity
If high production speed is achieved, then productivity is improved, but manufacturing precision and quality control become more difficult
Solution Approach 1:
The patent implements continuous impregnation and processing operations without interruption, maintaining constant temperature and pressure conditions throughout the process. This continuous operation enables high production speed while ensuring consistent impregnation quality through automated control systems that monitor and adjust parameters in real-time, preventing quality variations even at high speeds.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method results in high-speed production of impregnated fibrous materials with uniform impregnation, high fiber volume rates, and controlled porosity, enhancing the mechanical strength and reproducibility of composite parts while avoiding environmental and health risks associated with organic solvents.
Implementation Method 1
a step for heating the thermoplastic matrix in order to obtain ribbons of fibrous material impregnated homogeneously
Implementation Method 2
heating the thermoplastic matrix in order to obtain ribbons of fibrous material impregnated homogeneously
Implementation Method 3
heating the thermoplastic matrix in order to obtain ribbons of fibrous material impregnated homogeneously, in particular in the core, with reduced and controlled porosity
Data Source
AI summary
A method of manufacturing an impregnated fibrous material including a fibrous material made of continuous fibers and at least one thermoplastic polymer matrix, the method including pre-impregnating the fibrous material while it is in the form of a roving or several parallel rovings with the thermoplastic material and heating the thermoplastic matrix for melting, or maintaining in the molten state, the thermoplastic polymer after pre-impregnation, the at least one heating step being carried out by means of at least one heat-conducting spreading part (E) and at least one heating system, with the exception of a heated calendar, the roving or the rovings being in contact with part or all of the surface of the at least one spreading part (E) and partially or wholly passing over the surface of the at least one spreading part (E) at the level of the heating system.